CN101495046B - e.g. shafts for electromechanical surgical equipment - Google Patents

Abstract

An e.g. flexible shaft, comprising: an elongate outer sheath; at least one drive shaft disposed within the outer jacket; a ring non-rotatably mounted to at least one rotatable drive shaft; and at least one light source mounted within the shaft such that, when the at least one rotatable drive shaft is rotated, the ring alternately blocks light from the light source and allows light from the light source to be detected. The shaft may also include a humidity sensor disposed within the outer sheath of the shaft and configured to detect moisture within the outer sheath. The shaft may include a coupling connecting a distal end of the outer sheath to a surgical accessory and a proximal end of the outer sheath to a remote power console.

Description

e.g. shafts for electromechanical surgical equipment

Cross-incorporation of related applications

This application claims U.S. Provisional Patent Application Serial No. 60/703,227, filed July 27, 2005, entitled "Flexible Shaft, e.g., for an Electro-Mechanical Surgical Device" priority, the entire contents of which are incorporated herein by reference.

field of invention

The present invention relates to a shaft, and more particularly, to a shaft for use with electromechanical surgical equipment.

Background technique

Various surgical systems are known. For example, a surgical system may include an electromechanical drive device removably coupled to a surgical accessory. Such an electromechanical drive device is described, for example, in U.S. Patent Application Serial No. 09/723,715, entitled "Electro-Mechanical Surgical Device," filed November 28, 2000 and now assigned U.S. Patent No. .6,793,652, U.S. Patent Application Serial No. 09/836,781, filed April 17, 2001, entitled "Electro-Mechanical Surgical Device," and filed June 22, 2001, entitled "Electro-Mechanical Surgical Device" Mechanical Surgical Device (electromechanical surgical equipment) "U.S. Patent Application Serial No. 09/887,789, the entire content of each of them is incorporated herein by reference. The particular surgical instruments and systems described suffer from a number of disadvantages, which are described in additional detail below. Typically, conventional surgical systems may include shafts that provide limited torque, do not provide the user with a precisely determined position of the associated instruments and operative elements of the system, do not provide moisture detection functionality, and are often complex and expensive to assemble.

Contents of the invention

In an exemplary embodiment of the present invention, a flexible shaft for coupling a surgical accessory to an electromechanical drive device is provided, the flexible shaft comprising: a flexible, elongated outer sheath made of an autoclavable material; and at least one drive shaft disposed in said outer sheath. In an example embodiment of the invention, the flexible shaft includes a moisture sensor disposed within the outer sheath configured to detect moisture within the flexible outer sheath. The flexible shaft may also include one or more rotatable drive shafts connected to the drive shaft of the motor system of the electromechanical drive device to rotate and thereby operate the surgical accessory. Each rotatable drive shaft of the flexible shaft may include orthogonal rings with lugs that alternately block and allow light from the light source to be transmitted through the fiber optic cable to a controller configured to detect and interpret The optical signal is received through the fiber optic cable and the position and/or orientation of a component, such as an anvil or a cutting blade, of a surgical accessory, such as a surgical stapler, for example, is determined in response to the signal. The flexible shaft may also include additional channels for providing irrigation and/or suction to the surgical site through the flexible shaft.

In an exemplary embodiment of the invention, a shaft includes: an elongated outer sheath; at least one rotatable drive shaft disposed within the outer sheath; a member rotatable from at least one a drive shaft extending radially and configured to rotate with the at least one rotatable drive shaft; and at least one light source mounted within the outer sheath, wherein when the at least one rotatable drive shaft rotates, the The member alternately blocks light from the light source and allows light from the light source to be detected. The member may be, for example, one lug or two lugs extending from an orthogonal ring mounted on at least one rotatable drive shaft. Furthermore, two light sources may be provided mounted at the distal end of the shaft, for example mounted at approximately 90 degrees to each other with respect to the axis of the at least one rotatable drive shaft.

Description of drawings

Figure 1 is a perspective view of an electromechanical surgical device according to an example embodiment of the present invention.

Figure 2 is a perspective view of a flexible shaft according to an example embodiment of the invention.

FIG. 3(A) is a side view of the flexible shaft shown in FIG. 2 .

3(B) is a bottom view illustrating a partial sectional view of the flexible shaft taken along line 3B-3B shown in FIG. 3(A).

FIG. 3(C) is a plan view illustrating a partial sectional view of the flexible shaft taken along line 3C-3C shown in FIG. 3(A).

FIG. 4(A) is an enlarged cross-sectional view of a second coupling member according to an example embodiment of the present invention when assembled.

FIG. 4(B) is a front perspective view of a second coupling, an exploded view showing some components of the second coupling, according to an example embodiment of the present invention.

4(C) is a rear perspective view of the second coupling shown in FIG. 4(B) when partially assembled, illustrating some additional features of the second coupling.

4(D) and 4(E) are front and rear perspective views, respectively, of a distal contact assembly according to an example embodiment of the present invention when assembled.

Figure 4(F) is a rear perspective view of the distal contact assembly with an exploded view showing some components of the distal contact assembly.

Figure 4(G) is a front view of the distal sensor assembly according to an example embodiment of the invention when assembled.

FIG. 4(H) is a schematic diagram of a humidity sensor coupled to a data transmission cable.

FIG. 5(A) is an enlarged cross-sectional view of the first coupling member when assembled according to an example embodiment of the present invention.

FIG. 5(B) is a front perspective view of a first coupling showing some components of the first coupling in an exploded view according to an example embodiment of the present invention.

6 is a side view, partially in section, of a flexible shaft of the electromechanical surgical device illustrated in FIG. 1 .

7 is a cross-sectional view of the flexible shaft taken along line 7-7 shown in FIG. 6 .

8 is a rear end view of the first coupling member of the flexible shaft illustrated in FIG. 2 .

FIG. 9 is a front end view of the second coupling member of the flexible shaft illustrated in FIG. 2 .

10 is a schematic diagram of a motor arrangement of the electromechanical surgical device illustrated in FIG. 1 .

11 is a schematic illustration of the electromechanical surgical device illustrated in FIG. 1 .

Fig. 12 is a schematic diagram of the orthogonal ring device of the flexible shaft illustrated in Fig. 4(B).

13 is a schematic illustration of a surgical accessory and/or flexible shaft storage device.

14 is a schematic diagram of a wireless remote control unit of the electromechanical surgical device illustrated in FIG. 1 .

15 is a schematic diagram of a wired remote control unit of the electromechanical surgical device illustrated in FIG. 1 .

Detailed ways

Referring to FIG. 1 , a perspective view of an electromechanical surgical device 10 according to an example embodiment of the present invention can be seen. Electromechanical surgical device 10 may include, for example, a remote powered console 12 including a housing 14 having a front panel 15 . Mounted on the front panel 15 is a display device 16 and indicators 18a, 18b, which will be more fully described hereinafter. A shaft 20 may extend from the housing 14 and may be detachably secured thereto by a first coupling 22 . Shaft 20 may be flexible, rigid, articulated, articulated, and the like. Although the shaft 20 is referred to below as the flexible shaft 20, it should be understood that the flexible shaft 20 is only one example embodiment of the shaft 20 and that the shaft 20 is by no means limited to a flexible arrangement. The distal end 24 of the flexible shaft 20 may include a second coupling 26 adapted to removably secure a surgical instrument or accessory to the distal end 24 of the flexible shaft 20 . The surgical instrument or accessory may be, for example, a surgical stapler, surgical cutter, surgical stapler-cutter, linear surgical stapler, linear surgical stapler-cutter, circular surgical stapler, circular surgical stapler-cutter, surgical clip applier Forceps, surgical clip ligators, surgical clamps, vasodilator devices, lumen dilator devices, scalpels, fluid delivery devices, or any other type of surgical instrument. These surgical instruments are described, for example, in the United States of America entitled "A Stapling Device for Use with an Electromechanical Driver Device for Use with Anastomosing, Stapling, and Resecting Instruments" Patent application serial number No. 09/324,451 and the current authorized number is U.S. Patent No. 6,315,184, titled "Electromechanical Driver Device for Use with Anastomosing, Stapling, and Resecting Instruments (used for electromechanical drive equipment for engaging, stapling, and resecting instruments) )” U.S. Patent Application Serial No. 09/324,452 and the current authorized U.S. Patent No. 6,443,973, U.S. Patent Application Serial No. 09/351,534 entitled “Automated Surgical Stapling System (Automated Surgical Stapling System)” And the current authorization number is U.S. Patent No. 6,264,087, the U.S. patent application serial number No. .09/510,926 and the current authorization number is U.S. Patent No. 6,378,061, a U.S. patent application titled "Electromechanical Driver and Remote Surgical Instruments Attachment Having Computer Assisted Control Capability" Serial No. 09/510,927 and the current authorized number is U.S. Patent No. 6,716,233, the U.S. Patent Application Serial No. No. entitled "ATissue Stapling Attachment for Use with an Electromechanical Driver Device" .09/510,931 and the current authorization number is U.S. Patent No. 6,533,157, named "A FluidDelivery Mechani sm for Use with Anastomosing, Stapling, and Resecting Instruments (for jointing, anastomosis and resection instrument fluid delivery mechanism)" U.S. Patent Application Serial No. 09/510,932 and is now authorized as U.S. Patent No. 6,491,201, and title U.S. Patent Application Serial No. 09/510,933 for "A Fluid Delivery Device for Use with Anastomosing, Stapling, and Resecting Instruments (for joining, stapling, and resectioning instruments)" and the current authorization number is U.S. Patent No. .6,488,197, each of which is hereby incorporated by reference in its entirety.

FIG. 2 is a perspective view of the flexible shaft 20 . It should be understood that while the flexible shaft 20 is shown and described herein as being detachably coupled to the remote power console 12, in other example embodiments the flexible shaft 20 may be permanently coupled to the remote power console 12 or be integrated with the remote power console 12. Other aspects and features of the flexible shaft 20 will be described below with reference to FIGS. 3(A)-15.

FIG. 3(A) is a side view illustrating the flexible shaft 20 . According to an example embodiment, the flexible shaft 20 includes a tubular sheath 28 that may include a coating or other sealing arrangement to provide a watertight seal between its internal passage 40 and the environment. Sheath 28 may be formed from a tissue compatible sterile elastomeric material. Sheath 28 may also be formed from an autoclavable material. Sheath 28 may be formed from a material having high lubricity or relatively high lubricity. For example, sheath 28 may comprise Teflon ^™ (i.e., a fluoropolymer such as polytetrafluoroethylene—"PTFE"), silicone, a Teflon ^™ /silicone combination—such as, for example, SIL-KORE ^™ (manufactured by WL Gore & Associates).

FIG. 3(B) is a bottom view illustrating a partial cross-sectional view of the flexible shaft 20 taken along line 3B-3B shown in FIG. 3(A). FIG. 3(B) illustrates the proximal end of the flexible shaft 20 and the first coupling member 22 in cross-section. Other aspects and features of the first coupling member 22 of the flexible shaft 20 will be described below with reference to FIGS. 5(A), 5(B) and 8 .

FIG. 3(C) is a plan view illustrating a partial cross-sectional view of the flexible shaft 20 taken along line 3C-3C shown in FIG. 3(A) . FIG. 3(C) illustrates the distal end of the flexible shaft 20 and the second coupling member 26 in cross-section. Other aspects and features of the second coupling member 26 of the flexible shaft 20 will be described below with reference to FIGS. 4(A)-4(H) and 9 .

FIG. 4(A) is an enlarged cross-sectional view of the second coupling member 26 when assembled according to an example embodiment of the present invention. FIG. 4(B) is a front perspective view of the second coupling 26 according to an example embodiment of the present invention, with an exploded view showing some components of the second coupling. FIG. 4(B) shows the distal assembly 2231. First ends of two distal cable end assemblies 2078 are disposed within distal assembly 2231 . A second end of each distal cable end assembly 2078 is disposed within a respective aperture of distal connection assembly 2066 . A distal cable end 2082 is configured for each distal cable end assembly 2078 . A first end of the distal cable end 2082 has longitudinally disposed holes serving as connection means 66 and 68, respectively, as will be described in more detail below. The distal most surface of the distal assembly 2231 opens through openings to the connection means 66, 68, and is also provided with the connection means 70 and openings 101b and 102b to the irrigation and suction channels 101 and 102 respectively, as discussed further below. Pivot bearing 330 is mounted at approximately the midpoint of the outer surface of distal cable end 2082 . A second end of the distal cable end 2082 engages the distal orthogonal loop 2080 . Each drive cable 30, 32 (described in more detail below in conjunction with FIG. 6) is connected to each distal orthogonal ring 2080, and the drive cables 30, 32 are surrounded by a sleeve 377 made of, for example, Teflon®. Made of ^TM . Each drive cable 30 , 32 extends inside the flexible shaft 20 along the length of the flexible shaft 20 .

FIG. 4(C) is a rear perspective view of the second coupling member 26 shown in FIG. 4(B) when partially assembled, illustrating some additional features of the second coupling member. As shown in FIG. 4(C), the distal cable end assembly 2078 engages each aperture of the distal optical module 2085. The distal optical module 2085 is connected to the distal pressure die holder 2069 in which the pivot bearing 330 is disposed. On the distal side of pivot bearing 330 are mounted seals 764 . The distal end of the distal pressure die holder 2069 is connected to the distal housing 2237. A distal contact assembly 2073, which cannot be seen from Figure 4(C) but is illustrated in Figures 4(D)-4(F) , fits within the distal pressure die block 2069. A distal sensor assembly 2233 is also mounted within the distal pressure die set 2069, the distal sensor assembly 2233 is not visible from Figure 4(C) but is illustrated in Figure 4(G).

4(D) and 4(E) are front and rear perspective views, respectively, of the distal contact assembly 2073 when assembled, according to an example embodiment of the invention. Figure 4(F) is a rear perspective view of the distal contact assembly 2073, with an exploded view showing some of the components of the distal contact assembly. Referring to FIG. 4(F), the distal contact assembly 2073 includes a distal PCB 2232 having a plurality of through holes. Two LEDs 379 are mounted on the proximal side of the distal PCB 2232. An insulator 2084 is mounted on the distal side of the distal PCB 2232, the insulator 2084 having holes generally corresponding to the holes in the distal PCB 2232. Five sleeves 214 disposed within contact sheath 2238 extend through insulator 2084 and the aperture of distal PCB 2232. The distal end of the contact sheath 2238 is capped by a contact insulator block 2189 .

FIG. 4(G) is a front view of the distal sensor assembly 2233 when assembled, according to an example embodiment of the invention. The distal sensor assembly 2233 includes a distal sensor PCB 2234 with a pair of holes therein. In addition, the distal sensor assembly 2233 has four sensors 217, such as phototransistors, mounted thereon.

Returning to FIG. 4(A), it shows all the individual components of the assembled second coupling member 26 in cross-section. FIG. 4(A) also illustrates a humidity sensor 990 mounted within the second coupling 26 . Additional details of the humidity sensor 990 are shown in FIG. 4(H). Referring to FIG. 4(H), a humidity sensor 990 is coupled to the data transmission cable 38 to signal the presence of moisture (eg, transmit detected moisture data to) the remote power console 12 . Moisture present within flexible shaft 20 may cause corrosion of flexible shaft 20 components such as, for example, rotatable drive shafts 30 , 32 and electronic or electrical components disposed within flexible shaft 20 . Depending on and/or based on the detected moisture data, the remote power console 12 may notify the user of the presence of moisture, eg, via an audio signal or a visual signal. The humidity sensor 990 may include a first printed lead 995 and a second printed lead 996 each printed on a board member 997 and connected to the data transmission cable 38 . The presence of moisture will change the electrical conductivity between the printed leads 995, 996, eg, the resistance between the printed leads 995, 996 will vary depending on the amount of moisture present. It should be appreciated that humidity sensor 990 may additionally or alternatively be disposed within the elongated sheath of flexible shaft 20 and coupled to, for example, data transmission cable 38 .

FIG. 5(A) is an enlarged cross-sectional view of the first coupling member 22 when assembled according to an example embodiment of the present invention. FIG. 5(B) is a front perspective view of the first coupling member 22 according to an example embodiment of the present invention, with an exploded view showing some components of the first coupling member. As shown in FIG. 5(B), the first coupling member 22 includes a proximal component 2095 . Proximal assembly 2095 includes data connector 60 . Proximal PCB assembly 2030 is disposed within proximal assembly 2095 and mounted to an inner surface at the proximal end of proximal assembly 2095 . Proximal drive shaft 2102 passes through the cutout area of proximal PCB assembly 2030 and communicates with a hole in the proximal end of proximal assembly 2095 . The proximal drive shafts 2102 have non-circular—for example hexagonal—drive connections 44, 48 at their proximal ends to engage corresponding drive shafts of motor arrangements within the remote power console 12, as will be described below. A more specific description will be given. The distal end of the proximal drive shaft 2102 is engaged with a proximal crimp terminal 2071 which connects the distal end of the proximal drive shaft 2102 to a drive cable extending within the flexible shaft 20 in a non-rotatable manner, for example Proximal end of 30,32. The drive cables 30, 32 are connected at their opposite ends, eg, in a non-rotatable manner, to a distal cable end assembly 2078 located within the first coupling 22, as previously described.

FIG. 6 is a side view, partially in section, of a flexible shaft 20 according to an example embodiment of the present invention. A first rotatable drive shaft 30 and a second rotatable drive shaft 32 may be disposed within the flexible shaft 20 and extend along the entire length of the flexible shaft. Furthermore, according to various exemplary embodiments of the present invention, within the flexible shaft 20 may be provided steering cables 34 , 35 , 36 and 37 , data transmission cables 38 , optical cable sets 39 , flushing channel 101 and suction channel 102 . It should be noted that channels such as 101, 102 may be used for purposes other than irrigation and/or aspiration of the surgical site, for example may be used to pass surgical instruments therethrough. Additionally, it should be noted that while the cable set 39 is shown as a single bundle of cables, in other example embodiments the cables may be provided separately. Any number of fiber optic cables may be used, as described below. FIG. 7 is a cross-sectional view of the flexible shaft 20 taken along line 7-7 shown in FIG. 6 and also illustrates several cables 30 , 32 , 34 - 39 and channels 101 , 102 . Each of the number of cables 30, 32, 34-39 may be housed within a respective sheath.

The first rotatable drive shaft 30 and the second rotatable drive shaft 32 may be configured, for example, as highly flexible drive shafts, such as twisted or helical drive cables. It should be appreciated that the torque transfer characteristics and capabilities of such highly flexible drive shafts may be limited. It should also be appreciated that surgical instruments such as surgical stapler attachments or the like, or other attachments that are detachably attached to flexible shaft 20 , may require higher torque input than the torque transmitted through drive shafts 30 , 32 . Thus, the drive shafts 30, 32 may be configured to transmit low torque but high speed, the high speed/low torque being converted to low speed/high torque by a gear arrangement such as a remote control of the flexible shaft 20. Surgical instruments or accessories and/or remote power consoles 12 are provided at the distal and/or proximal ends. It should be understood that such gearing may be located at any suitable location along the power train between a motor in housing 14 and an attached surgical instrument or other device removably attached to flexible shaft 20. among other accessories. Such a gear arrangement may be provided in a surgical instrument or other accessory that is detachably attached to the flexible shaft 20 . Such gear devices may include, for example, spur gear devices, planetary gear devices, harmonic gear devices, cycloidal drives, epicyclic gear devices, and the like.

Referring now to FIG. 8 , a schematic view of the rear end of the first coupling member 22 can be seen. The first coupling part 22 comprises a first connection device 44 and a second connection device 48 each arranged in a rotatable manner relative to the first coupling part 22 . Each connection means 44 , 48 includes a respective protrusion 46 , 50 extending through the proximal-most surface of the first coupling member 22 . As shown in FIG. 8, each protrusion 46, 50 may be hexagonally shaped. However, it should be understood that the protrusions 46, 50 may have any shape and configuration to non-rotatably couple and rigidly attach the connection means 44, 48 to the respective drive shafts of the motor apparatus housed within the housing 12. , described more fully below. It will be appreciated that complementary recesses may be provided on each drive shaft of the motor arrangement, thus driving the drive elements of the flexible shaft 20 as described below. It should also be understood that protrusions may be provided on the drive shaft and complementary recesses on the coupling means 44,48. Any other coupling device configured to couple the connection means 44, 48 to the drive shaft of the motor device in a non-rotatable but releasable manner may be configured.

One of the connection means 44 , 48 is non-rotatably fixed to the first drive shaft 30 and the other of the connection means 44 , 48 is non-rotatably fixed to the second drive shaft 32 . The remaining two of the connection means 44 , 48 , 52 , 56 are engaged with transmission elements configured to apply tension to the steering cables 34 , 35 , 36 , 37 and thus to manipulate the distal end 24 of the flexible shaft 20 . The first coupling 22 may include openings 101a, 102a connected to the irrigation channel 101 and the suction channel 102, respectively, for introducing fluid into and/or draining away from the surgical site.

The data transmission cable 38 is electrically and logically connected to the data connector 60 . The data connector 60 includes, for example, electrical contacts 62 in a number corresponding to and equal to the number of individual wires housed in the data cable 38 . The first coupling member 22 includes a key structure 42 for properly orienting the first coupling member 22 toward a mating complementary coupling device disposed on the housing 12 . Such keying 42 may be provided on one or both of the first coupling member 22 and a complementary mating coupling device provided on the housing 12 . The first coupling 22 may comprise a quick-connect type of connection means that engages the first coupling 22 to the housing 12 by, for example, a simple push-in action. A seal may be provided in combination with any of the number of connection means 44, 48, 60 to provide a watertight seal between the interior of the first coupling 22 and the environment.

Referring now to FIG. 9 , a schematic view of the front end of the second coupling member 26 of the flexible shaft 20 can be seen. The second coupling member 26 includes a first connecting device 66 and a second connecting device 68, each connecting device being rotatably arranged relative to the second coupling member 26 and each being non-rotatably fixed to a corresponding The distal ends of the first and second drive shafts 30, 32. A quick-connect type fitting 64 may be provided on the second coupling 26 for releasably securing a surgical instrument or accessory to the second coupling. The quick connect type fitting 64 may be, for example, a swivel quick connect type fitting, a bayonet type fitting, or the like. A key structure 74 may be provided on the second coupling 26 for proper alignment of the surgical instrument or accessory with the second coupling 26 . Keying 74 or other means for properly aligning a surgical instrument or accessory with flexible shaft 20 may be provided on one or both of second coupling 26 and the surgical instrument or accessory. Furthermore, quick-connect type fittings can be provided on surgical instruments or accessories. A data connector 70 having electrical contacts 72 is also provided in the second coupling part 26 . Similar to the data connector 60 of the first coupling 22, the data connector 70 of the second coupling 26 includes contacts 72 that are electrically and logically connected to the wires of the data transmission cable 38 and the data The contacts 62 of the connector 60 . The connection means 66, 68, 70 may be provided in combination with a seal to provide a watertight seal between the interior of the second coupling 26 and the environment. The second coupling 26 may include openings 101b, 102b connected to the irrigation channel 101 and the suction channel 102, respectively, for introducing fluid to and/or draining fluid from the surgical site.

Electromechanical drive elements configured to drive the aforementioned drive shafts 30 , 32 to operate the electromechanical surgical device 10 and surgical instruments or accessories attached to the second coupling 26 are disposed within the housing 14 of the remote powered console 12 . In an example embodiment schematically illustrated in FIG. 10 , five electric motors 76 , 80 , 84 , 90 , 96 each powered by a power source may be provided in the remote power console 12 . However, it should be understood that any suitable number of motors may be provided and that the motors may be operated from battery power, line current, DC power, electrically controlled DC power, or the like. It should also be understood that the motor may be connected to a DC power supply which is connected to the line current and which supplies the motor with operating current from the line current.

Figure 10 schematically illustrates one possible arrangement of the motor. When the first coupling member 22 , and thus the flexible shaft 20 , is engaged with the housing 14 to drive the first drive shaft 30 and the first connection means 66 of the second coupling member 26 , the output shaft of the first motor 76 78 engages with the first connection means 44 of the first coupling part 22 . Similarly, when the first coupling member 22—and thus the flexible shaft 20—engages with the housing 14 to drive the second drive shaft 32 and the second connection means 68 of the second coupling member 26, the second motor 80 The output shaft 82 of the first coupling member 22 engages with the second connecting device 48 .

As mentioned above, the flexible shaft 20 may include steering cables, such as the steering cables 34 , 35 , 36 and 37 , which may be used to manipulate the flexible shaft 20 . Figure 10 also illustrates one possible motor arrangement in which steering cables may be utilized in those example embodiments that include a flexible shaft 20 with steering cables. For example, FIG. 10 illustrates that when the first coupling member 22—and thus the flexible shaft 20—engages with the housing 14 to drive the first and second steering cables 34, 35 through the first pulley arrangement 88, the second The output shaft 86 of the three motors 84 engages with the third connection means 52 of the first coupling part 22 . When the first coupling 22 - and thus the flexible shaft 20 - is engaged with the housing 14 to drive the third and fourth steering cables 36, 37 through the second pulley arrangement 94, the output shaft 92 of the fourth motor 90 Engages with the fourth connection means 56 of the first coupling part 22 . The third and fourth motors 84, 90 can be fixed to the carriage 100, and the carriage 100 can be selectively moved by the output shaft 98 of the fifth motor 96 between a first position and a second position to make the third and fourth The motors 84, 90 are selectively engaged and disengaged from each pulley arrangement 88, 94, thus allowing the flexible shaft 20 to become taut and maneuverable or loosen as desired. It should be understood that other mechanical, electrical or electromechanical mechanisms may be utilized to selectively engage and disengage the manipulation structure. The arrangement and construction of the motor can be described, for example, in US Patent Application Serial No. 09/ 510,923 and Grant No. as described in US Patent No. 6,715,565, the entire contents of which are incorporated herein by reference.

It should be understood that any one or more of the motors 76, 80, 84, 90, 96 may be a high speed/low torque motor or a low speed/high torque motor. As noted above, the first rotatable drive shaft 30 and the second rotatable drive shaft 32 may be configured to transmit high speeds and low torques. Accordingly, the first motor 76 and the second motor 80 may be configured as high speed/low torque motors. Alternatively, the first motor 76 and the second motor 80 may be configured as low speed/high torque motors with corresponding first rotatable drive shafts 30 and second rotatable drive shafts disposed between the first motor 76 and the second motor 80 . A torque-reducing/speed-increasing gear arrangement between the rotating drive shafts 32 . Such torque-reducing/speed-increasing gearing may include, for example, spur gearing, planetary gearing, harmonic gearing, cycloidal drive arrangements, epicyclic gearing, and the like. It should be appreciated that any such gear arrangement may be provided within the remote power console 12 or in the proximal end of the flexible shaft 20 , such as in the first coupling 22 , for example. It should be appreciated that gear arrangements are provided at the distal and/or proximal ends of the first rotatable drive shaft 30 and/or the second rotatable drive shaft 32 to prevent entanglement and breakage thereof.

Referring now to FIG. 11 , a schematic illustration of an electromechanical surgical device 10 can be seen. Controller 122 is disposed within housing 14 of remote power console 12 and is configured to control all functions and operations of electromechanical surgical device 10 and any surgical instruments or accessories attached to flexible shaft 20 . A storage unit 130 is provided and may include a storage device such as a ROM part 132 and/or a RAM part 134 . ROM component 132 is in electrical and logical communication with controller 122 via line 136 , and RAM component 134 is in electrical and logical communication with controller 122 via line 138 . RAM component 134 may include any type of random access memory such as, for example, magnetic storage, optical storage, magneto-optical storage, electronic storage, or the like. Similarly, ROM component 132 may comprise any type of read-only memory, such as a removable storage device such as a PC card or PCMCIA type device. It should be appreciated that ROM component 132 and RAM component 134 may be provided as a single unit or as separate units, and that ROM component 132 and/or RAM component 134 may be provided in the form of a PC card or PCMCIA type device. The controller 122 is also connected to the front panel 15 of the housing 14 and, more specifically, to the display device 16 by line 154 and to the indicators 18a, 18b by respective lines 156,158. Lines 116 , 118 , 124 , 126 , 128 electrically and logically connect controller 122 to first motor 76 , second motor 80 , third motor 84 , fourth motor 90 , and fifth motor 96 , respectively. A wired remote control unit (“RCU”) 150 is electrically and logically connected to controller 122 by line 152 . A wireless RCU 148 is also provided and communicates via a wireless link 160 with a receive/transmit unit 146 which is connected to the transceiver 140 via line 144. Transceiver 140 is electrically and logically connected to controller 122 by line 142 . Wireless link 160 may be, for example, an optical link such as an infrared link, a radio link, or any other form of wireless communication link.

Switching device 186 , which may be, for example, a bank of DIP switches, may be connected to controller 122 by line 188 . The switch device 186 may, for example, select a language among a plurality of languages for displaying information and prompts on the display device 16 . Information and prompts may relate, for example, to the operation and/or status of electromechanical surgical device 10 and/or any surgical instruments or accessories attached thereto.

According to an example embodiment of the invention, each orthogonal ring 2080 is disposed within the second coupling member 26 and is configured to respond to rotation of the corresponding first and second drive shafts 30, 32 and according to the corresponding first and second drive shafts. The rotation of the drive shafts 30, 32 outputs a signal. The signal output by each quadrature ring 2080 may indicate the rotational position of each drive shaft 30, 32 and its direction of rotation. Although quadrature ring 2080 is described as disposed within second coupling 26, it should be understood that quadrature ring 2080 may be disposed anywhere between the motor system and the surgical instrument or accessory. It should be appreciated that positioning the orthogonal ring 2080 within the second coupling 26 or at the distal end of the flexible shaft 20 provides precise determination of drive shaft rotation. If the orthogonal ring 2080 is provided at the proximal end of the flexible shaft 20, the winding of the first rotatable drive shaft 30 and the second rotatable drive shaft 32 can cause measurement errors.

FIG. 12 is a schematic diagram of a quadrature loop 2080 setup. An orthogonal ring 2080 having a first lug 20801 and a second lug 20802 is non-rotatably mounted on one of the drive shafts 30,32. The orthogonal ring 2080 device also includes first and second light sources 217, such as light emitting diodes, phototransistors, etc., disposed approximately 90° apart about the longitudinal or rotational axis of the drive shafts 30, 32. °. Additionally, the orthogonal loop 2080 device may include a fiber optic cable set 39 , for example, for passing light along the length of the flexible shaft 20 between the light source 217 and the remote powered console 12 . The first lug 20801 and the second lug 20802 of the orthogonal ring 2080 are configured to alternately block and allow light from the light source 217 to pass through the fiber optic cable to the remote power console 217 . It should be understood that although the orthogonal rings 2080 are described and shown herein as a separate structure mounted to each rotatable drive shaft 30, 32, any structure that rotates with the rotatable drive shafts 30, 32 and performs each orthogonal ring 2080 may be used. Functional components such as the rotatable drive shafts 30, 32 themselves may have integral structures such as lugs. Based on the light emitted from each light source 217 received by the remote power console 12, the angular position of the drive shafts 30, 32 can be determined within a quarter of a turn and the direction of rotation of the drive shafts 30, 32 can be determined. The output of each quadrature loop 2080 is passed to the controller 122 . By tracking the angular position and rotational direction of drive shafts 30 , 32 based on output signals from quadrature loop 2080 , controller 122 is thereby able to determine the position and/or status of components of surgical instruments or accessories connected to electromechanical surgical device 10 . That is, by counting the number of revolutions of the drive shafts 30 , 32 , the controller 122 can determine the position and/or status of components of surgical instruments or accessories connected to the electromechanical surgical device 10 . It should be understood that any number of lugs may be provided depending on the desired angular motion resolution.

For example, the second coupling member 26 of the flexible shaft 20 can be removably attached to a surgical stapler accessory that includes an anvil bar that extends and retracts to clamp a portion of tissue to the anvil. Above, the surgical stapler attachment also includes a staple driver/cutter that cuts the portion of tissue and drives a set of staples against the anvil base to staple the portion of tissue. Extension and retraction of the anvil may be accomplished by operation of the first motor 76 , while extension and retraction of the staple drivers/cutters may be accomplished by operation of the second motor 80 . The pitch of the drive shaft used to drive the anvil and the pitch of the drive shaft used to drive the staple driver/cutter can be predetermined and known quantities such that the advance distance of the anvil and the staple driver/cutter Can be a function of the rotation of the respective drive shaft 30 , 32 and can be determined based on the rotation of the respective drive shaft 30 , 32 . By determining the absolute position of the anvil and staple driver/cutter at a point in time, based on the output signals from each quadrature ring 2080 and the known pitch of the anvil drive shaft and staple driver/cutter drive shaft , and then the relative displacement of the anvil and the staple driver/cutter can be used to determine the absolute position of the anvil and the staple driver/cutter. The absolute positions of the anvil and staple driver/cutter can be fixed and determined when the circular surgical stapler attachment is initially coupled to the flexible shaft 20 . Alternatively, the positions of the anvil and staple drivers/cutters relative to separate components, such as surgical stapler accessories, can be determined based on output signals from orthogonal ring 2080 .

Referring again to FIG. 11 , the surgical stapler attachment and the flexible shaft 20 may include memory units 174 , 850 respectively electrically and logically connected to the controller 122 via data cables within the flexible shaft 20 . The storage unit 174, 850 may be in the form of, for example, an EEPROM, EPROM, or the like. Figure 13 schematically illustrates a storage unit 174 according to an example embodiment of the present invention. The storage unit 850 may have a similar arrangement as shown in FIG. 13 . As can be seen in FIG. 13 , data connector 272 includes contacts 276 each electrically and logically connected to storage unit 174 by a corresponding line 278 . Storage unit 174 is configured to store, for example, serial number data 180 , accessory type identification (ID) data 182 , and usage data 184 . The storage unit 174 may additionally store other data. Both serial number data 180 and ID data 182 may be configured as read-only data. In an example embodiment, serial number data 180 is data that uniquely identifies a particular surgical instrument or accessory, while ID data 182 is data that identifies the type of accessory such as a circular surgical stapler accessory, a linear surgical stapler accessory, etc., for example. Usage data 184 represents usage of a particular accessory, such as the number of times the anvil of a surgical stapler accessory connected by flexible shaft 20 has been advanced or the number of times a staple driver/cutter of a circular surgical stapler accessory has been advanced or actuated.

It should be understood that each type of surgical instrument or accessory attached to the distal end 24 of the flexible shaft 20 may be designed and configured for one-time use only or for multiple uses. Surgical instruments or accessories can also be designed and configured to be used a predetermined number of times. Accordingly, usage data 184 may be used to determine whether a surgical instrument or accessory has been used and whether the number of uses has exceeded the maximum number of uses allowed. As described more fully below, attempting to use a surgical instrument or accessory after the maximum number of uses allowed generates an ERROR status.

It should be understood that the above discussion of any particular surgical accessory, such as a circular surgical stapler accessory, is merely an example of a surgical accessory that may be used in conjunction with the flexible shaft 20 . It should also be understood that any other type of surgical instrument or accessory, such as those listed above, may also be used in conjunction with the flexible shaft 20 . Regardless of the particular type of surgical instrument or accessory, in example embodiments of the invention, the surgical instrument or accessory may include coupling elements that may be necessary for proper operation of the surgical instrument or accessory as well as include the storage unit 174 . Although the drive shaft and motor are described herein as performing a specific function of a circular surgical stapler accessory, it should be understood that the drive shaft and motor may perform the same or other functions with other types of surgical instruments or accessories.

Referring again to FIG. 11 , according to an example embodiment of the present invention, controller 122 is configured to read ID data 182 from storage unit 174 of the surgical instrument or accessory when the surgical instrument or accessory is initially connected to flexible shaft 20, and controller 122 is configured to The ID data 880 is read from the storage unit 850 of the flexible shaft 20. The storage units 174, 850 may be electrically and logically connected in parallel to the controller 122 through the line 120 of the data transmission cable 38, or alternatively, the storage units 174, 850 may be connected to the controller 122 through respective dedicated lines.

The controller 122 may prevent the surgical device 10 from driving the flexible shaft 20 based on the read usage data 870 of the flexible shaft 20 . As noted above, a particular flexible shaft 20 may be designed and configured to be used once, multiple times, or a predetermined number of times. Accordingly, the usage data 870 may be read by the controller 122 to determine whether the flexible shaft 20 has been used more than the maximum number of uses allowed. If the maximum number of uses has been exceeded, the controller 122 may block subsequent attempts to use the flexible shaft 20 .

Additionally, the controller 122 may write usage data 870 to the storage unit 850 of the flexible shaft 20 . The written usage data 870 may include information such as the number of rotations of one or both of the rotatable drive shafts 30, 32, the number of uses of one or both of the rotatable drive shafts 30, 32, the number of times the rotatable drive shaft 30 , 32 one or both of the number of actuations, and/or the number of times the flexible shaft 20 has been used, etc. It should be understood that the written usage data 870 may include any form of information suitable to indicate any usage-related changes in state of the flexible shaft 20 .

Based on the read ID data 182 , the controller 122 is configured to read or select an operating program or algorithm corresponding to the type of surgical instrument or accessory connected to the flexible shaft 20 from the storage unit 130 . The storage unit 130 is configured to store operating programs or algorithms for each possible type of surgical instrument or accessory, and the controller 122 reads the ID data 182 from the storage unit 130 based on the ID data 182 read from the storage unit 174 of the attached surgical instrument or accessory. Select and/or read an operating program or algorithm. As noted above, storage unit 130 may include removable ROM components 132 and/or RAM components 134 . Accordingly, the operating programs or algorithms stored in the storage unit 130 may be updated, added, deleted, improved or otherwise modified when necessary. The operating programs or algorithms stored in the storage unit 130 can be customized based on, for example, the user's special needs. For example, a data input device such as a keyboard, mouse, pointing device, touch screen, etc. may be connected to the storage unit 130 through, for example, a data connection port to facilitate customization of an operating program or algorithm. Alternatively or additionally, an operating program or algorithm may be customized and pre-programmed into memory unit 130 remote from electromechanical surgical device 10 . It should be appreciated that serial number data 180 and/or usage data 184 may also be used to determine which of a plurality of operating programs or algorithms to read or select from storage unit 130 . It should be understood that the operating program or algorithm may alternatively be stored in the memory unit 174 of the surgical instrument or accessory and transmitted to the controller 122 via the data transmission cable 38 . Once the appropriate operating program or algorithm is read or selected by the controller 122 or the appropriate operating program or algorithm is delivered to the controller 122, the controller 122 performs the operation according to the user through the wired RCU 150 and/or wireless RCU 148. to run an operating program or algorithm. As noted above, the controller 122 is electrically and logically connected to the first motor 76, the second motor 80, the third motor 84, the fourth motor 90, and the fifth motor 96 via lines 116, 118, 124, 126, 128. , and control these motors 76, 80, 84, 90, 96 through the lines 116, 118, 124, 126, 128 according to the read, selected or transmitted operating program or algorithm.

Referring now to FIG. 14, a schematic diagram of the wireless RCU 148 can be seen. The wireless RCU 148 includes a steering controller 300 having a plurality of switches 302, 304, 306, 308 disposed below a four-way rocker 310. The operation of the first and second steering cables 34 , 35 is controlled via the third motor 84 through the operation of the switches 302 , 304 by the rocker 310 . Similarly, operation of the switches 306 , 308 by the rocker 310 controls the operation of the third and fourth steering cables 36 , 37 via the fourth motor 92 . It should be appreciated that rocker 310 and switches 302, 304, 306, 308 are arranged such that operation of switches 302, 304 steers flexible shaft 20 in a north-south direction and operation of switches 306, 308 steers flexible shaft 20 in an east-west direction. East, west, south, and north are described herein with reference to corresponding coordinate systems. Alternatively, instead of joystick 310 and switches 302 , 304 , 306 , 308 , a digital joystick, analog joystick, etc. may be provided. Instead of switches 302, 304, 306, 308, potentiometers or any other type of actuator could also be used. The wireless RCU 148 also includes a steering engage/disengage switch 312, operation of which controls operation of the fifth motor 96 to selectively engage and disengage the steering mechanism. The wireless RCU 148 also includes a two-way rocker 314 having first and second switches 316, 318 operated therefrom. Operation of these switches 316, 318 controls certain aspects of the electromechanical surgical device 10 and any surgical instruments or accessories attached to the flexible shaft 20 according to an operating program or algorithm corresponding to the attached surgical instrument or accessory, if any. some functions. For example, when the surgical instrument is a circular surgical stapler attachment, operation of the two-way rocker 314 can control the advancement and retraction of the anvil. The wireless RCU 148 is provided with another switch 320, the operation of which can further control the electromechanical surgical device 10 and any attached to the flexible Shaft 20 for operation of surgical instruments or accessories. For example, when a circular surgical stapler attachment is attached to the flexible shaft 20, operation of the switch 320 results in the advancement or firing of the staple driver/cutter.

The wireless RCU 148 includes a controller 322, the controller 322 is electrically and logically connected with the switches 302, 304, 306, 308 through the circuit 324, electrically and logically connected with the switches 316, 318 through the circuit 326, and connected with the switch through the circuit 328 312 is electrically and logically connected to switch 320 through line 330 . The wireless RCU 148 may include indicators 18a', 18b' corresponding to the indicators 18a, 18b of the front panel 15 and a display device 16' corresponding to the display device 16 of the front panel. If indicators 18a', 18b' and display device 16' are provided, indicators 18a', 18b' are electrically and logically connected to controller 322 through respective lines 332, 334, and display device 16' is electrically and logically connected through line 336. ground and logically connected to the controller 322. Controller 322 is electrically and logically connected to transceiver 338 by line 340 , and transceiver 338 is electrically and logically connected to receiver/transmitter 342 by line 334 . A power source, not shown, such as a battery, may be provided in the wireless RCU 148 to power it. Thus, via wireless link 160, wireless RCU 148 can be used to control the operation of electromechanical surgical device 10 and any surgical instruments or accessories attached to flexible shaft 20.

Wireless RCU 148 may include switch 346 connected to controller 322 by line 348. Operating switch 346 passes the data signal to transmitter/receiver 146 via wireless link 160 . The data signal includes identification data that uniquely identifies the wireless RCU 148. Controller 122 utilizes this identification data to prevent unauthorized operation of electromechanical surgical device 10 and to prevent another wireless RCU from interfering with the operation of electromechanical surgical device 10 . Each subsequent transmission between wireless RCU 148 and electromechanical surgical device 10 may include identifying data. Accordingly, the controller 122 is able to differentiate between wireless RCUs and thus only allows a single, identifiable RCU 148 to control the operation of the electromechanical surgical device 10 and any surgical instruments or accessories attached to the flexible shaft 20.

Based on the position of the components of the surgical instrument or accessory attached to the flexible shaft 20 as determined from the output signals from the quadrature loop 2080, the controller 122 may selectively enable or disable operations corresponding to the attached surgical instrument or accessory. A program or algorithm defines the functionality of the electromechanical surgical device 10 . For example, when the surgical instrument or accessory is a circular surgical stapler accessory, the actuation function controlled by operation of switch 320 may be inhibited unless it is determined that the space or gap between the anvil and the body part falls within acceptable limits . The space or gap between the anvil and the body part is determined based on output signals from quadrature ring 2080, as described more fully above. It should be understood that the switch 320 itself is still operable, but the controller 122 does not perform the corresponding function unless it is determined that the aforementioned space or gap falls within an acceptable range. Additionally, if the humidity sensor 990 detects moisture within the flexible shaft 20, the actuation function controlled by the operation of the switch 320 may be disabled.

Referring now to FIG. 15, a schematic diagram of a wired RCU 150 can be seen. In an example embodiment, the wired RCU 150 includes substantially the same control elements as the wireless RCU 148, and further description of these elements will be omitted. Similar elements are marked in FIG. 15 with an accompanying prime. It should be appreciated that the functions of electromechanical surgical device 10 and any surgical instruments or accessories attached to flexible shaft 20 may be controlled by wired RCU 150 and/or wireless RCU 148. The wired RCU 150 may be used to control the functions of the electromechanical surgical device 10 and any surgical instruments or accessories attached to the flexible shaft 20, such as in the event of a battery failure of the wireless RCU 148.

As mentioned above, the front panel 15 of the housing 14 includes a display device 16 and indicators 18a, 18b. The display device 16 may comprise an alphanumeric display device such as an LCD display device. Display device 16 may also include audio output devices such as speakers, buzzers, and the like. Controller 122 operates and controls display device 16 according to an operating program or algorithm corresponding to a surgical instrument or accessory attached to flexible shaft 20 , if present. If no surgical instrument or accessory is attached, the controller 122 will read or select a default operating program or algorithm or pass the operating program or algorithm to the controller 122, thereby controlling the operation of the display device 16 and the electromechanical surgical setup 10 other aspects and functions. If a circular surgical stapler attachment is attached to the flexible shaft 20, the display device 16 may display data representing the gap between the anvil and the body part, determined, for example, from the output signal of the orthogonal ring 2080, as described herein described more fully in .

Similarly, the controller 122 operates and controls the indicators 18a, 18b according to an operating program or algorithm corresponding to the surgical instrument or accessory attached to the flexible shaft 20, if present. Indicators 18a and/or indicators 18b may include audio output devices such as speakers, buzzers, etc. and/or visual indicator devices such as LEDs, lights, lights, and the like. If a circular surgical stapler attachment is attached to the flexible shaft 20, the indicator 18a may indicate, for example, that the electromechanical surgical device 10 is on, and the indicator 18b may, for example, indicate whether the gap between the anvil and the body part is determined to be fell within acceptable ranges, as described more fully herein. It should be understood that although only two indicators 18a, 18b are depicted, any number of additional indicators may be provided if necessary. Furthermore, it should be understood that while a single display device 16 is described, any number of additional display devices may be provided if necessary.

Respective controllers 322, 322' similarly operate and control the display device 16' and indicators of the wireless RCU 150 according to an operating program or algorithm associated with the surgical instrument or accessory, if present, attached to the flexible shaft 20 18a', 18b' and the display device 16" and indicators 18a", 18b" of the wired RCU 148.

Claims (21)

1. A shaft comprising: elongated outer sheath; at least one rotatable drive shaft disposed within said outer sheath; a member extending radially from the at least one rotatable drive shaft and configured to rotate with the at least one rotatable drive shaft; and at least two light sources mounted within said outer sheath and arranged at approximately 90 degrees to each other relative to the axis of said at least one rotatable drive shaft, wherein said member alternately blocks light from said light source and allows light from said light source to be detected as said at least one rotatable drive shaft rotates to determine said value based on quarter-turn increments. angular position and rotational direction of the at least one rotatable drive shaft. 2. The shaft of claim 1, wherein the member is a lug. 3. The shaft of claim 2, wherein the member includes two lugs extending from an orthogonal ring mounted on the at least one rotatable drive shaft. 4. The shaft of claim 1, wherein the at least two light sources comprise two light sources mounted to the distal end of the shaft. 5. The shaft of claim 1, wherein the shaft is flexible. 6. The shaft of claim 1, wherein the shaft is rigid. 7. The shaft of claim 1, wherein the shaft is articulated. 8. The shaft of claim 1, wherein the shaft is hinged. 9. The shaft of claim 1, wherein the at least two light sources are light emitting diodes. 10. The shaft of claim 9, wherein the outer sheath is autoclavable. 11. The shaft of claim 9, wherein the outer sheath comprises a fluoropolymer and/or silicone material. 12. The shaft of claim 1, further comprising at least one fiber optic cable for transmitting light from the light source. 13. The axle of claim 12, wherein the member and the at least two light sources are configured such that light transmitted from the at least two light sources can be interpreted by the controller to determine the at least one rotatable The rotation of the drive shaft. 14. The axle of claim 13, wherein the controller is located in a remote power console. 15. The shaft of claim 14, further comprising: A first coupling at a proximal end of the shaft configured to removably couple the shaft to the remote power console. 16. The shaft of claim 15, further comprising: A second coupling connected to the distal end of the outer sheath, the second coupling configured to be removably coupled to a surgical accessory. 17. The shaft of claim 16, wherein the controller is configured to determine a position of a component of the surgical accessory based on an interpretation of the transmitted light. 18. The shaft of claim 1, further comprising: A humidity sensor disposed within the outer sheath, the humidity sensor configured to detect moisture within the outer sheath. 19. The shaft of claim 1, further comprising: A storage unit is provided in the shaft. 20. The axle of claim 19, wherein the data stored by the storage unit includes at least one of serial number data, identification data, and usage data. 21. The axle of claim 20, further comprising: A data transmission cable disposed within the shaft, wherein the storage unit is logically and electrically connected to the data transmission cable.

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